S.

A ENGINEERING COLLEGE
DEPARTMENT OF MECHANICAL ENGINEERING
SIXTH SEM MECHANICAL ME 2352
DESIGN OF TRANSMISSION SYSTEMS
UNIT I
DESIGN OF TRANSMISSION SYSTEMS FOR FLEXIBLE ELEMENTS
PART A
1. Name the four types of belts used for transmission of power?
2. Why are the idler pulleys used in belt drive?
3. When do you use stepped pulley drive?
4. When do you use fast and loose pulley drive?
5. What is the centrifugal effect on belt
6. What are the losses in belt drives?
7. What is wipping? How it can be avoided in belt drive?
8. What type of belt would you prefer if the centre distance between the pulley is small?
9. State reasons for V belt drive being performed to flat belt drive?
10. What is a V flat drive?
11. What are the materials used for V grooved pulleys?
12. When do you prefer a wire rope drive?
13. Write any four wire rope applications?
14. What are the advantages of wire ropes when compared with chains and fiber ropes?
15. How are wire ropes designated?
16. What do you understand by 16*19 constructions in wire ropes?
17. List out the various stresses induced in the wire ropes?
18. While designing a wire rope drive always larger sleeve diameter is preferred justify the
Statement?
19. When do you prefer a chain drive to a belt or rope drive?
20. Give any three applications of chain drives?
21. What is an offset in a roller chain?
22. What is back sliding in chain drives?
23. What you mean by galling of roller chain?




PART B

1. It is required to select a flat belt drive for a fan running at 360rpm.which is driven by a 10kw,
1440rpm motor. The belt drive is open type and space available for a center distance of 2m
approximately. The diameter of a driven pulley is 1000mm.

2. Design a belt drive to transmit20kw at 720rpm aluminium rolling machine, the speed ratio being
3. The distance between the pulley is3m.diameter of rolling machine pulley is 1.2m.

3. A leather belt 125mm wide and 6mm thick, transmit power from a pulley with the angle of lap
150 and =0.3. If the mass of1m3 of leather is 1mgand the stress in the belt is not to exceed 2.75
Mpa, find the maximum power that can be transmitted and the corresponding speed of the belt.

4. A centrifugal pump running at 340rpm is to be driven by a 100kw motor running at
1400rpm.the drive is to work for at least for 20hrs every day. The center distance between the motor
shaft at the pump shaft is 1200mm.suggest a suitable multiple v-belt drive for this application.


5. A truck equipped with a 9.5 kW engine uses a roller chain as the final drive to the rear axle .The
driving sprocket runs at 900 rpm and driven sprocket at 400rpm with center distance of
approximately 600mm .select the roller chain.


6. A workshop crane is lifting a load of 25kN through a wire rope and a hook. Te weight of the hook
etc is 15kN. The rope drum diameter may be taken as 30 times the diameter of the rope. The load is
to be lifted with an acceleration of 1 m/s
2.
Calculate the diameter of the wire rope. Take a factor of
safety of 6 and Youngs modulus for the wire rope 80 kN/mm
2
. The ultimate stress may be taken as
1800 MPa. The cross-sectional area of the wire rope may be taken as 0.38 times the square of the
wire rope diameter.

7 .Two shafts whose centers are 1 meter apart are connected by a V belt drive. The driving pulley
is supplied with 95 kW power and has an effective diameter of 300mm. it runs at 1000 rpm, while
the driven pulley runs at 375 r.p.m. The angle of groove on the pulleys is 40
0
. Permissible tension in
400 mm
2
cross sectional area belt is 2.1 MPa. The material of the belt has density of 1100 kg/ mm
3.

The driven pulley is overhung, the distance of the centre from the nearest bearing being 200 mm
.

The coefficient of friction between belt and pulley rim is 0.28. Estimate the number of belts
required.

8. A crane is lifting a load of 18 KN through a wire rope and a hook. The weight of the hook etc., is
10kN. The load is to be lifted with an acceleration of 1m/sec
2.
Calculate the diameter of the wire
rope. The rope diameter may be taken as 30 times the diameter of the rope. Take a factor of safety
of 6 and Youngs modulus for the wire rope 0.8 x 10
5
N/mm
2.
The ultimate stress may be taken as
1800 N/mm
2.
The cross-sectional area of the wire rope may be taken as 0.38 times the square of the
wire rope diameter.

9. Design a chain drive to actuate a compressor from a 12 KW electric motor at 900 rpm, the
compressor begin 250 rpm. Minimum centre distance should be 500 mm, the chain tension may be
adjusted by shifting the motor on rails. The compressor is to work 8 hour/day.

10. Design a chain drive to actuate a compressor from 15kW electric motor running at 1,000 r.p.m,
the compressor speed being 350 rpm. The minimum centre distance is 500 mm. the compressor
operates 15 hours per day. The chain tension may be adjusted by shifting the motor
Unit-II

SPUR GEARS AND PARALLEL AXIS HELICAL GEARS

PART A
1. What are the advantages of toothed gears over the types of transmission system?
2. Back lash for spur gears depends on which two factors?
3. Define transmission ratio with reference to spur gears?
4. Define module?
5. In a pair of spur gears, the module is 6mm. Determine the circular pitch and the diametral pitch?
6. State the condition of correct gearing (or) state the low of gearing?
7. What are the common forms of fear tooth profile?
8. What are the standard interchangeable tooth profiles?
9. Define pitch circle with reference to spur gears?
10. What are the materials used for gear manufacturing?
11. When do you use non-metallic gears?
12. What are the non metallics used as gears?
13. Why is pinion made harder than gear?
14. List out the carious methods of manufacturing a gear.
15. What are the main types of gear tooth failure?
16. What are the assumptions made in deriving lewis equation?


PART B
1. A pinion with 25 teeth and rotating at 1200rpm drives a gear which rotates at 200rpm and
module is 4mm.calculate the center distance between the gears.
2. Design a spur gear drive required to transmit 45 kW at pinion speed of 800 rpm. The velocity
ratio 3.5:1the teeth are 20 full depths involute with 18 teeth on the pinion. Both the pinion gear is
made of steel with a maximum safe static stress of 180N / mm
2
.
3. Design a pair of helical gears to transmit 30kW power at a speed reduction ratio of 4:1. The input
shaft rotates at 2000 rpm. Take helix and pressure angles equal to 25
0
and 20
0
respectively. The number
of teeth on the pinion may be taken as 30.

4. Design a straight spur gear drive to transmit 8 kW. The pinion speed is 720 rpm and the speed
ratio is 2. Both the gears are made of the same surface hardened carbon steel with 55RC and core
hardness less than 350 BHN. Ultimate strength is 720 N/mm
2
and yield strength is 360 N/ mm
2.


5. A motor shaft rotating at 1500 rpm has to transmit 15kW to a low speed shaft with a speed
reduction of 3:1. Assume starting torque to be 25% higher than the running torque. The teeth are
20
0
involutes with 25 teeth on the pinion. Both the pinion and gear are made of C45 steel. Design a
spur gear drive to suit the above conditions and check for compressive and bending stresses and
plastic deformations. Also sketch the spur gear drive.

6. A helical gear with 30
0
helix angle has to transmit 35kW at 1500 rpm. With a speed reduction
ratio 2.5. If the pinion has 24 teeth, determine the necessary module, pitch diameter and face width
for 20
0
full depths the teeth. Assume 15Ni 2Cr 1 Mo 15 material for both pinion and wheel.

7. An electric motor is to be connected to a reciprocating pump through a gear pair. The gears are
overhanging in their shafts. Motor speed = 1440 rpm. Speed reduction ratio = 5. Motor power = 36.8
kW. The gears are to have 20
0
pressure angles. Design a spur gear drive.

8. A pair of helical gears subjected to moderate shock loading is to transmit 37.5kW at 1750 r.p.m.
of the pinion. The speed reduction ratio is 4.25 and the helix angle is 15
0.
The service is continuous
and the teeth are 20
0
FD in the normal plane. Design the gears, assuming a life f 10,000 hours

9. A compressor running at 300 rpm is driven by a15 KW, 1200 rpm motor through a 14
0
full depth
spur gears .The centre distance is 375 mm .The motor pinion is to be of C30 forged steel hardened and
tempered, and the driven gear is to be of cast iron. Assuming medium shock condition, design the gear
drive.

UNIT-III
BEVEL, WORM AND CROSS HELICAL GEARS

PART A
1. Who do you prefer helical gears than spur gears?
2. Where do we use helical gears?
3. What is the major disadvantage of single helical gear? How can you over come that difficulty?
4. What hands of helix are used in paraller helical gears?
5. Define axial pitch of a helical gear?
6. Why is the crossed helical gear drive mostly not used for power transmission?
7. Under what situation, bevel gears are used?
8. Differentiate a straight bevel gear and spiral bevel gear?
9. What are the advantages of spiral bevel gears over straight bevel gears?
10. What is zero bevel gear?
11. What is the difference between an angular gear and a miter gear?
12. Define back cone distance for bevel gears,?
13. Under what situation, worm gears are used?
14. Where do we use worm gears?
15. What is irreversibility in worm gears?
16. Define normal pitch of a worm gear?

PART B
1 A kW motor running at 1200 rpm drives a compressor at 780 rpm through a 90
0
bevel gearing
arrangement. The pinion has 30 teeth. The pressure angle of the teeth is 20
0
. Both the pinion and
gear are made of heat treated cast iron grade 35. Determine the cone distance, average module and
face width of the gears.

2. Design a pair of bevel gears for two shafts whose axes are at right angles. The power transmitted
is 25kW. The speed of the pinion is 300 rpm and the gear is 120 rpm.

3. A 2 kW power is applied to a worm shaft at 720 rpm. The worm is of quadruple start with 50mm as
pitch circle diameter. The worm is of quadruple start type with 50mm as pitch circle diameter. The
worm gear has 40 teeth with 5mm module. The pressure angle in the diametral plane is 20
0.
Determine
(i) the lead angle of the worm, (ii) velocity ratio, and (ii) centre distance. Also, calculate efficiency of the
worm gear drive, and power lost in friction

4 A pair of straight tooth bevel gears has a velocity ratio of 4/3. The pitch diameter of the pinion is 150
mm. The face width is 50mm. The pinion rotates at 240 rev/min. The teeth are 5mm module, 14 1
0

involutes. If 6 kW is transmitted, determine (i) the tangential force at the Mean radius (ii) the pinion
thrust force (iii) the gear thrust force. Draw the free body diagrams indicating the forces.

5. Design a worm gear drive with a standard centre distance to transmit 7.5 kW from a warm
rotating at 1440 rpm to a warm wheel at 20 rpm.

6. Design the teeth of a pair of bevel gears to transmit 18.75 kW at 600 rpm of the pinion. The
velocity ratio should be about 3 and the pinion should have about 20 teeth which are full depth 20
0

involutes. Find the module, face width, diameter of the gears and pitch core angle for both gears.

7. A 90
0
degree straight bevel gear set is needed to give a 3:1 reduction. Determine the pitch cone
angle, pitch diameter, and gear forces if the, 25 degree pressure angle pinion ahs 15 teeth of pitch
circle diameter, 4, and the transmitted power is 8 HP at 550 pinion rpm.

8. Design a worm gear drive to transmit 22.5 kW at a worm speed of 1440 rpm. Velocity ratio is 24:1.
An efficiency of at least 85% is desired. The temperature rise should be restricted to 40
0
C. Determine
the required cooling area

9. A speed reducer wait is to be designed for an input of 11.25kW with a transmission ratio of 20. The
speed of the hardened steel worm is 1500 rpm. The worm wheel is to be made of bronze. The tooth form
is to be 20
0
in volute.

10 Design a bevel gear drive to transmit 3.5 kW with the following specifications: speed ratio = 4;
driving shaft speed = 200 r.p.m.; drive is non-reversible; material for pinion is steel; material for
wheel is cast iron; and life 25000 hours.

11.Design a worm gear drives to transmit a power of 22.5 kW. The worm speed is 1440 r.p.m. and
the speed of the wheel is 60 r.p.m. The drive should have a minimum efficiency of 80% and above.
Select suitable materials for worm and wheel and decide upon the dimensions of the drive.



UNIT-IV
DESIGN OF GEAR BOXES
PART A
1. What situations demand use if gear boxes?
2. Write any two requirements of a speed gear box?
3. Why G.P. series is selected for arranging the speeds in gear box?
4. List any two methods used for changing speeds in gear box?
5. What are preferred numbers?
6. What is step ratio? Or Define progression ratio?
7. What is kinematic arrangement as applied to gear boxes?
8. What does the ray-diagram of gear box indicates?
9. State any three basic rules to be followed while designing a gear box?
10. What are the possible arrangements to achier 12 speeds from a gear box?
11. List out the possible arrangement to achieve 16 speed gear box?
12. What is a speed reducer?

PART B
1. Design a 12 speed gearbox
The speed range required 100 to 355rpm
a) Draw the ray diagram,
b) Draw the kinematic arrangement
c) Calculate the no. of teeth on each gear
2. The maximum and minimum speed of a 6 speed gear box is to be 1600 rpm and 500 rpm
respectively. Construct the speed diagram and the kinematic arrangement of the gearbox.

3. Design a nine speed gear box for a milling machine with speed ranging from 56-900rpm. The
output speed is 720rpm; make a neat sketch of the gearbox. Indicate the no of teeth on all the gears
and their speeds.

4. A gearbox is to give 18 speeds for a spindle of a milling machine. The drive is from an electric
motor of 3.75kw at 1440rpm. Maximum and minimum speeds of the spindle are to be around
650rpm and 35rpm respectively. Find the speed ratios which will give the desired speeds and draw
the structural diagram and kinematic arrangement of the drive.


5. Design a gearbox, for the following data:
No of speeds required=16; min speed=100rpm; max speed=560rpm;
Draw diagram and kinematic arrangement.

6. The minimum and maximum speed of a six speed box is to be 160 and 1500rpm. Construct the
kinematic arrangement and the ray diagram of the gearbox.

7. A gearbox is to be designed to provide 12 output speeds ranging from 160 to 200rpm. The input
speed of motor is 1600rpm. Choosing a standard speed ratio construct the speed diagram and the
kinematic arrangement.

UNIT-V
DESIGN OF CAM CLUTCHES AND BRAKES
PART A
1) What is the function of a clutch?
2. Give examples for axial and radial friction clutch?
3. What are the properties required of the material used as a friction surface?
4. Name few commonly used friction materials?
5. Clutches are usually designed on the basic of uniform wear, why?
6. Distinguish between dry and wet operation of clutches?
7. Why a service factor is used for calculating the design capacity of clutch?
8. In case clutch semi-cone angle should be greater than 12 why?
9. What is the difference between cone and centrifugal clutches?
10. Compare disc clutches and cone clutches?
11. List out the elements of internal expanding rim clutches?
12. Why seat dissipation in necessary in clutches?
13. Given the reaction to find temperature rise in clutches?
14. What is the friction of a brake?
15. Differentiate a brake and a clutch?
16. Differentiate a brake and a dynamometer?
17. Give example for radial and axial brakes?
18. What is a self locking brake?
19. What you meant by self energizing brakes?
20. Two blocks diametrically opposite to each other are used in a block brake. Why?
21. What is the significance of pressure angle in cam design?
22. What is undercutting in cams?
23. What is jerk?
24. What is the function of a cam?
25. What are the different types of followers?
26. How can the thrust of the follower be reduced?

PART B
1 A multi disk clutch consists of five steel plates and four bronze plates. The inner and outer
diameters of friction disks are 75mm and 150mm respectively. The coefficient of friction is 0.1 and
the intensity of pressure is limited t 0.3 N/mm
2.
Assuming the uniform wear theory, calculate (i) the
required operating force, and (ii) power transmitting capacity at 750 rpm.

2 An automotive type internal expanding double shoe brake is shown in figure 15b. The face
width of the friction lining is 40 mm and the intensity of normal pressure is limited to 1 N/mm
2
.
The coefficient of friction is 0.32. The angle
1
can be assumed to be zero. Calculate (i) the actuating
force P, and (ii) the torque absorbing capacity of the brake.

3. A leather faced conical clutch has cone angle of 30
0
.The pressure between the contact surfaces is
limited to .35N/mm
2
and the breath of the conical surface is not to exceed 1/3 of the mean radius .
Find the dimensions of the contact surface to transmit 22Kw at 2000 rpm .Also calculate the force
required to engage the clutch. .Take =0.15

4. A single plate clutch , both side being effective is required to connect a machine
shaft to a driver shaft which runs at 500rpm .The moment of inertia of the rotating parts of the
machine is 1Kgm
2
.The inner and the outer radii of the friction discs are 50mm&100mm respectively
.Assuming uniform pressure of 0.1N/mm
2
and =0.25, determine the time taken for the machine to
reach full speed when the clutch is suddenly engaged. Also determine the power transmitted by the
clutch, the energy dissipated during the clutch slip and the energy supplied to the machine during
engagement.

4. Draw the displace time , velocity time and the acceleration time curves for the follower in order
to satisfy the following conditions
(1) Stroke of the follower 25mm
(2) Outstroke takes place with SHM during 90
0
of cam rotation
(3) Return stroke takes with SHM during 75
0
of cam rotation
(4) Cam rotates with a uniform speed of 800 rpm

5. A radial cam rotates at 1200 rpm with the follower rising 20mm with SHM in1500of the cam
rotation .The roller is 32mm in diameter and the prime circle is 80mm in diameter. Check whether
undercutting will occur.